Pinch Seal Fill And Open Shipping Sack

ABSTRACT

A shipping sack includes a body including a first end and a second end, opposed lateral sides, and opposed first and second panels. The first end is a first closed end defined by a first end portion of the first panel extending beyond a first end portion of the second panel and the first end portion of the first panel is folded-over and secured to the first end portion of the second panel. The second end is a second closed end defined by a second end portion of the second panel extending beyond a second end portion of the first panel and the second end portion of the second panel is folded-over and secured to the second end portion of the first panel. A fill opening is located on the second panel and extends between the lateral sides and is disposed at a location adjacent the first closed end.

RELATED APPLICATIONS

The present application relates to U.S. application Ser. No. 61/658,293 filed on Jun. 11, 2012, Ser. No. 61/788,868 filed Mar. 15, 2013 and Ser. No. 61/810,736 filed Apr. 11, 2013, all of which are incorporated herein in their entirety.

BACKGROUND

Exemplary embodiments herein generally relate to shipping bags or sacks and, more particularly, toward a woven shipping bag or sack having top and bottom ends that are closed and sealed prior to filling of the shipping sack.

Woven shipping bags or sacks are popular shipping containers for pet food, fertilizer, seed and other materials that are shipped and sold in relatively large-sizes, from 15 to 100 pounds. Such woven shipping sacks are typically formed from a fabric mesh that is impregnated with a heat sealable plastic, such as polypropylene. The sacks may have multiple layers, wherein one layer facilitates sealing and bonding of the ends by heat/adhesive. One style of these shipping sacks is known as a pinch bottom open mouth (PBOM) bulk material bag or sack. Such a PBOM sack is initially formed as a tube, sometimes with pleated or folded side walls. One end (i.e., a bottom end) of the PBOM sack is presealed by the manufacturer by folding the bottom end over, typically with a 1.75 to 2.25 inch (44 to 57 mm) fold, and sealing by adhesives or welding so that the customer receives a sack having a securely closed bottom end and an open top end. The customer fills the sack via the open top end, and subsequently seals the filled sack by folding the top end over, similar to what was done to seal the bottom end (i.e., using adhesive and/or welding), so as to arrive at a securely sealed and filled sack. One drawback of such an arrangement is that it is sometimes difficult for the end user to open the sack, which now must be accomplished by cutting or tearing the sack near one of the closed ends.

BRIEF DESCRIPTION

According to one aspect, a shipping sack comprises a body including a first end and a second end longitudinally spaced from the first end, opposed lateral sides, and opposed first and second panels. The first end is a first closed end defined by a first end portion of the first panel extending beyond a first end portion of the second panel and the first end portion of the first panel is folded-over and secured to the first end portion of the second panel. The second end is a second closed end defined by a second end portion of the second panel extending beyond a second end portion of the first panel and the second end portion of the second panel is folded-over and secured to the second end portion of the first panel. The body further includes a fill opening located on the second panel. The fill opening extends between the lateral sides and disposed at a location adjacent the first closed end.

According to another aspect, a method of forming a shipping sack comprises providing a blank defining a first longitudinal axis and a second axis transverse to the first axis, the blank including a first end and a second end longitudinally spaced from the first end; providing at least one first fold line extending parallel to the first axis, the first fold line separating the blank into a first panel and a second panel; folding the blank along the first fold line, the blank now defining a tube including open first and second ends, first and second opposed panels and opposed lateral sides; providing a pair of spaced second fold lines, each of the second fold lines extending parallel to the transverse axis, one of the second fold line located on the first panel adjacent the first end, the other of the second fold lines located on the second panel adjacent the second end; folding the first end and the second end along the second fold lines, securing the first end to the second panel to define a closed first end, and securing the second end to the first panel to define a closed second end; and cutting the second panel in a direction parallel to the transverse axis at a location adjacent the first end to form a fill opening.

According to another aspect, a shipping sack comprises a body including a first end and a second end longitudinally spaced from the first end, opposed lateral sides, and opposed first and second panels. The first end is a first closed end defined by a first end portion of the first panel extending beyond a first end portion of the second panel and the first end portion of the first panel is folded-over and secured to the first end portion of the second panel. The second end is a second closed end defined by a second end portion of the second panel extending beyond a second end portion of the first panel and the second end portion of the second panel is folded-over and secured to the second end portion of the first panel. The body further includes a fill opening located on the second panel. The fill opening extends between the lateral sides and is disposed at a location adjacent the first closed end. The fill opening includes opposed ends, each end is spaced a predetermined distance from the lateral sides such that the fill opening has a width smaller than a width of the body.

Further, in accordance with the present disclosure, the shipping sack is initially formed as a tube having pleated or folded side walls, generally planar front and rear walls, and open bottom and top distal ends. Each of the top and bottom distal ends of the shipping sack is folder over and sealed to provide sack having sealed top and bottom ends. Before or after sealing of the top distal end, the shipping sack is cut in a direction transverse to its length at a location near the top distal end to form a fill opening. The fill opening extends across the front wall of the shipping sack, and terminates a distance from side edges of the front wall such that the fill opening is smaller than the width of the sack. The fill opening is spaced a distance from the sealed top end, and provides access for the customer to the interior of the shipping sack. The sack is filled with material through the fill opening. After filling, the sealed top end of the sack is folded down over the fill opening and sealed to the front wall of the sack at a sealing strip, thereby covering and closing the fill opening so as to re-seal the sack for shipping to the end user.

In further accordance with the present disclosure, a portion of the front wall of the sack, which will be engaged with the sealed top end of the sack when it is folded down over the fill opening, is treated with a release layer, such as a lacquer coating or release coating as is known in the art. Providing the release material at this location facilitates the end user opening of the sack by pealing open the folded-over top end of the sack to reveal the fill opening, which may now be used to gain access to the material received in the sack.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 illustrates an exemplary shipping sack according to the present disclosure.

FIG. 2 is a plan view of a blank for forming the shipping sack of FIG. 1.

FIGS. 3-8 illustrate one end of the blank of FIG. 2 being folded to form a closed end of the shipping sack of FIG. 1.

FIG. 9 illustrates the shipping sack of FIG. 1 being filled with a product via a fill opening provided adjacent the closed end of the shipping sack.

FIGS. 10 and 11 illustrate the closed end of the shipping sack of FIG. 9 being folded over to close the fill opening.

FIG. 12 illustrates the closed end of the shipping sack of FIG. 11 being opened to at least partially reveal the fill opening.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

It should, of course, be understood that the description and drawings herein are merely illustrative and that various modifications and changes can be made in the structures disclosed without departing from the present disclosure. As used herein, the terms top, bottom, front and rear are considered to be relative terms, and are not meant to limit the orientation of the sack in any way and are used only for purposes of explaining the present disclosure. Further, the dimensions listed hereafter are examples only, and do not limit the sack to the listed dimensions. Also, insofar as numerous techniques and means are known in the art for sealing shipping sacks, and insofar as shipping sacks formed of various material combinations are known in the art, the present disclosure is not to be limited to any particular sealing technology or sack composition, but rather is intended to be a basic disclosure that is capable of use with all known and future developed sack compositions and sealing techniques.

Referring now to the drawings, wherein like numerals refer to like parts throughout the several views, FIG. 1 illustrates a pinch bottom open mouth (“PBOM”) sack 100 according to the present disclosure. As is well known, PBOM sacks are shipped from the manufacturer to the users in a flattened condition with one end of the sack closed, and the opposite end having an opening for filling the sack. In the present description, a top open end 102 of the sack 100 is sometimes referred to as the “consumer” end because the top end provides a means to fill the sack 100 and is typically closed by the consumer after the sack is filled, and a bottom closed end 104 of the sack 100 is sometimes referred to as the “manufactured” end because the bottom end is closed by the manufacture prior to shipping. As depicted, the sack 100 may be manufactured with gusseted sides 106, or may just as well be made with flat sides. According to one aspect, the open end 102 and closed end 104 are closed without a sewn closure, such that the closure has no holes that might allow for ingress or egress of contaminants.

It should also be appreciated that the exemplary sack 100 can be formed from a single blank 108 shown in FIG. 2. As is well known, raw material that is used to form the blank 108 can be supplied from a continuous roll stock. Rotating drum knives perforate the roll stock into a series of connected blanks that have the structure shown in blank 108, and which are eventually separated from one another by pulling the individual units (i.e., blanks 108) apart. The single blank 108 is depicted in a planar condition prior to its being formed into the sack 100. For reference purposes, the sack axis is defined as the axis extending in the direction of arrow A, that is, the axis that extends along the longitudinal axis of the formed sack. The cross-sack axis is transverse to the sack longitudinal axis.

As indicated above, the exemplary sack 100 may be manufactured with gusseted sides or flat sides, and in the embodiment illustrated herein the sides are gusseted. Specifically, gusset fold lines 120, 122, 124, 126, 128 and 130 are formed in blank 108 extending along the sack axis direction. In the figures, unless otherwise noted, fold lines provided on the blank 108 are shown in dashes. The gusset fold lines define the two major panels in the finished sack 100, identified herein as a front panel 132 and a rear panel 134. Rear panel 134 is split into two sections while the blank 108 is in the flattened condition of FIG. 1, one on either side of front panel 132 in blank 108, so that when the blank is formed into a tube the rear panel sections 134 at opposite sides of the front panel 132 are overlapped and sealed so that a seam extends along the rear panel in the sack axis direction. It will be also appreciated that if the sack were manufactured with flat sides rather than gussets, the three gusset fold lines on both sides of the sack would be replaced with a single fold line.

With continued reference to FIG. 2, the blank 108 has opposite side edges 142, 144 extending in the longitudinal axis direction and opposite end edges 146, 148 extending in the cross sack axis direction. According to one aspect of the present disclosure, each of the end edges 146, 148 can have steps formed therein. Specifically, and with reference to end edge 146, a first step 150 is defined by an edge portion 152 a on the left side of FIG. 2, and a corresponding edge portion 152 b at the right side of the figure. A second step 154 is defined by an edge portion 156 a and corresponding edge portion 156 b. A third step 160 is likewise defined by edge portions 162 a and 162 b, and a centrally located step 164 is defined completely across front panel 132 at an edge portion 166. According to one embodiment, a length (along the longitudinal axis) of the step 154 is about 12 mm to about 18 mm, a length of the step 160 is about 11 mm to about 14 mm, and a length of the step 164 is about 17 mm. As illustrated, edge portion 156 a of step 154 is between gusset fold lines 120 and 122 on the left side of FIG. 2, and that on the right side of the figure edge portion 156 b of step 154 is between gusset fold lines 128 and 130. Edge portion 162 a of step 160 is between gusset fold lines 122 and 124 on the one side, and edge portion 162 b of step 160 is between gusset fold lines 126 and 128 on the other side. Edge portion 166 of step 164 is the portion of blank 108 that extends across the front panel 132. It should be appreciated that that identical steps can be formed at the opposite end edge 148 of the blank 108, with the exception that the steps can extend inwardly toward the center of the blank. It should also be appreciated that the configuration of the blank 108 is by way of example only and that the blank 108 can be formed without the stepped configuration for the end edges 146, 148 without departing from the scope of the present disclose.

The formation of the exemplary sack 100 is illustrated in FIGS. 3-6. According to one aspect, the blank 100 is folded at gusset fold lines 120, 122 and 124 to form a gusset 180 on one lateral side edge 142 of the blank, and is folded at gusset fold lines 126, 128 and 130 to form an identical gusset 182 at the opposite lateral side edge 144 of the blank 100. Open opposite ends of the sack 100 (only end 190 is shown) are formed by folding the blank inwardly at gusset fold lines 120 and 130 so that the lateral edge 144 overlaps lateral edge 142. End 190 can be considered the open, consumer end 102 of the sack 100 and the opposite end (not shown) can be considered the closed, manufactured end 104 of the sack. The overlapping edges are adhered to one another in an appropriate manner, for example by sonic welding, heat sealing and/or thermowelding to define a seam 186 that runs along the length of the sack 100 in the sack longitudinal axis direction.

In this condition, and as best shown in FIGS. 4 and 5, the blank 108 can be considered a tube having edge portions 152 a and 152 b aligned, and the steps 154, 160 and 164 of end edge 146 are exposed at the open end 190. Adhesive, such as hot melt adhesive that is not tacky when dry, yet is able to be adhered later, can then be applied to desired exposed portions of the sack to facilitate closing of the end 190. Specifically, adhesive can be applied to the exposed portions of the gussets 180, 182 that define step 154 (i.e., edge portions 156 a, 156 b of step 154) and step 160 (i.e., edge portions 162 a, 162 b of step 160), and the exposed portion of front panel 132 that extends beyond the step 160 (i.e., edge portion 166 of step 164). Adhesive can also be applied to that portion of the front panel 132 that is between the steps 154 and 160. Adhesive is likewise can be applied to the corresponding portions of the blank 108 at the opposite open end. Breather openings 187 may be provided in the gussets 180 and 182 to facilitate the removal of excess air from the sack as it is being closed. It will be appreciated that the number, size and shape of the breather openings will be a function of the size of the bag, the degree to which it is filled, and the amount of air that needs to be removed during the closing operation. In order to maximize the integrity of the sack, the number, size and shape of the breather openings should be kept to a minimum. In many applications, where the sack is formed of a polymer material, it may be best to form the breather openings using a laser. Also, for applications where the breather openings are intended to allow air to escape after the sack is closed, for example, to allow the sack to relax after the sacks are piled or stacked together prior to shipping, it may be best to form very small openings with a laser (e.g., a series of small pinholes), such openings allowing air to slowly escape the sack, but at the same time such openings not allowing vermin to enter the sack and destroy the contents of the sack.

With reference now to FIG. 6, the open end 190 (i.e., the consumer end 102 of the exemplary sack 100) is then closed by folding the blank along a fold line 200 extending in the cross-sack axis adjacent the intersection between the steps 154 and 160 (i.e. near the aligned edge portions 156 a and 156 b) (see FIGS. 4 and 5). As this is done, the exposed portions of the gussets 180, 182 that define step 160 (i.e., edge portions 162 a, 162 b of step 160) come into contact with the exposed portions of the gussets 180, 182 that define step 154 (i.e., edge portions 156 a, 156 b of step 154). Further, the exposed portion of front panel 132 that extends beyond the step 164 (i.e., edge portion 166 of step 164) comes into contact with a section 206 of the rear panel 134 (i.e., over a section of the edge portions 152 a, 152 b of step 150). The folded-over closure section is, for example, pressed under heat against the facing portions of sack 100 and the surfaces are held together until they are joined firmly, thereby defining a folded and sealed portion 210. The opposite end of the blank 108 (not shown), which is the manufactured end 104, is closed in an identical manner to the consumer end 102, so as to create a sack having folded and sealed top and bottom ends (pinch sealed top and bottom).

It should be appreciated that the sealing of the consumer and manufactured ends 102, 104 can be by welding (ultrasonic, heat, laser, thermowelding etc.), and it is contemplated that several alternative end sealing techniques may be used. For example, each of the consumer end 102 and the manufactured end 104 of the sack 100 can be closed by a folding device adapted to fold the blank 108 as described above as the blank moves in a downstream direction on the folding device. At the downstream end of the folding device, a welding device associated with the folding device welds the closed folded-over ends (i.e. end 190) of the blank 108. The welding device can form welded seams that close the folded-over opposite ends of the blank without using in the welded seams a hot melt adhesive. Such a folding and welding system is more fully described in US Patent App. Pub. No. 2012/0227363, assigned to Miller Weldmaster Corporation, Navarre, Ohio, the disclosure being incorporated herein by reference. It will be appreciated that the sealing method that is employed will primarily be a function of the material used to form or construct the sack 100. Various materials may be employed, for example, without limitation, olefin polymer materials such as polypropylene or polyethylene terephthalate (PET), nylons, polyesters, and vinyl halide polymers such as polyvinyl chloride, and paper materials such as Kraft paper, and cloth-type materials formed of natural fibers such as cotton. The material employed may be formed from a single layer or it may comprise a multilayer structure such as, for example, a multiwall bag material commonly employed in the packaging industry that is formed of woven polypropylene.

FIG. 7 illustrates the consumer end 102 of the formed sack 100, which has already been folded-over at fold line 200 and sealed to the rear panel 134 of the sack as described above. It will be appreciated that the fold line 200 is at the top or distal edge of the formed sack 100 and that the original terminal or distal end of the sack 100 (i.e., the edge portion 166 of step 164 of the blank 108 the prior to folding) is now downwardly spaced from the fold line 200. The length between the fold line 200 and the original terminal end of the sack 100 (i.e., edge portion 166) is defined by a length of the folded and sealed portion 210, and this length is about 15 mm to about 28 mm.

At this point, a sealed sack 100 is completely manufactured and may be shipped to the customer as a closed and sealed construction. Shipping in this manner precludes introduction of contaminants into the interior of the sack 10. Alternatively, if desired, a fill opening 220, described below, may be cut into the rear panel 134 of the manufactured sack 100, and the sack with the fill opening 220 shipped to the customer. At the customer, if not previously formed, the fill opening 220 is cut into the rear panel 134 at a location spaced downwardly slightly from the folded and sealed portion 210 at the top end thereof. Fill opening 220 may be formed in various manners such as by sheering, or by use of a laser. The fill opening 220 extends across the rear panel in the cross-sack axis of the sack 100 and is spaced a distance from the lateral edges 106 of the formed sack 100. According to one embodiment, the fill opening 220 is spaced about 12 mm to about 25 mm from each of the lateral edges 106. As such, the fill opening 220 is relatively smaller in width than the opening provided at the consumer end 102 of the sack 100 prior to sealing of same (i.e., prior to forming of the sealed portion 210). Further, according to one aspect, a spacing of the fill opening 220 from the original terminal or distal end of the sack 100 (i.e., the edge portion 166 of step 164 of the blank 108 the prior to folding) is about 55 mm, and according to this aspect, a spacing of the fill opening 220 from the distal edge of the rear panel (i.e., the edge portions 152 a, 152 b of step 150) is about 10 mm. According to yet another aspect, a spacing of the fill opening 220 from the original terminal or distal end of the sack 100 (i.e., the edge portion 166 of step 164 of the blank 108 the prior to folding) is about 62 mm, and according to this aspect, a spacing of the fill opening 220 from the distal edge of the rear panel (i.e., the edge portions 152 a, 152 b of step 150) is about 14 mm to about 17 mm.

After the fill opening 220 is formed, a portion of the rear panel 134 may be moved or pulled away from the front panel 132 and the seal portion 210 to open or enlarge the fill opening 220, and the sack 100 is filled with material by the customer (FIG. 9). As such, filling occurs via the fill opening 220, which is disposed at a location intermediate the top and bottom distal ends 102, 104 of the sack 120. Then, the customer prepares the sack 100 for sealing by applying a release material, such as a lacquer, in a band 224 extending across the rear panel 134 of the sack 100 (see FIGS. 7 and 9). The release material may be applied before or after filling. The band 224 is located such that a top edge portion 226 of the sealed portion 210 (i.e., the portion downwardly adjacent the fold line 200 in FIG. 7), overlaps with the release material (FIGS. 10 and 11), thereby enabling the end user to easily peal the folded-over material back to gain access to the fill opening 220 (FIG. 12). However, it will be appreciated that the band 224 can applied using a printing press, printing screen or other application technique in a predetermined register position as part of the initial manufacture of the sack, and thus the customer then does not have to deal with band application issues. Also, it will be appreciated that in addition to lacquer, other common or known release agents employed in the packaging industry may be utilized. After the sack 100 is filled, a top end portion 230 of the sack 100 (which includes the sealed portion 210) is folded about a fold line 232 (FIG. 7). According to one embodiment, spacing between the fold line 232 and the fold line 200 is about 19 mm to about 38 mm. The folded-over portion 230 of the sack 100 is welded or adhesively glued to close or seal the fill opening 220. At this point, filling and sealing of the sack 100 is complete.

Although the fold line 232 is shown to be relatively below the fill opening 220, this is not required. Rather, the fold line 232 may be above the fill opening 220, as desired, so long as release of the folded-over portion of the sack reveals the fill opening. Further, although the fill opening 220 is depicted as being formed below the folded and sealed portion 210, it should be appreciated that the fill opening 220 can be formed in the folded and sealed portion 210.

As is evident from the foregoing, the shipping sack 100 comprises a body including a first end 102 and a second end 104 longitudinally spaced from the first end, opposed lateral sides 106, and opposed first and second panels 132, 134. The first end 102 is a first closed end defined by a first end portion of the first panel 132 extending beyond a first end portion of the second panel 134 and the first end portion of the first panel is folded-over and secured to the first end portion of the second panel. The second end 104 is a second closed end defined by a second end portion of the second panel 134 extending beyond a second end portion of the first panel 132 and the second end portion of the second panel is folded-over and secured to the second end portion of the first panel. The body further includes a fill opening 220 located on the second panel 134. The fill opening 220 extends between the lateral sides 106 and is disposed at a location adjacent the first closed end. The fill opening 220 includes opposed ends, each end is spaced a predetermined distance from the lateral sides 106 such that the fill opening has a width smaller than a width of the body. The body includes a first fold line 200 for folding over the first end portion of the first panel 132 to close the first end and define the first closed end. The body includes a second fold line 232 spaced from the first fold line 200 for folding over the closed first end. The fill opening 220 is located between the first fold line 200 and the second fold line 232, and the folded-over closed first end is secured to the second panel 134 to close the fill opening 220.

As is further evident from the foregoing, the woven shipping sack 100 permits the end user to easily open the shipping sack. Further, the present disclosure is directed toward a shipping sack 100 that has closed bottom and top ends 102, 104, and that is filled at a location spaced from one of the top and bottom ends. Additionally, the present disclosure is directed to a shipping sack 100 having both top and bottom ends 102, 104 pre-sealed which overcomes many difficult problems for customers (both the first customer who is involved with the filling of the sack, and the final customer who is the end-user). The advantages afforded by the shipping sack 100 of the present disclosure include but are not limited to the following: the pre-sealed sack 100 takes less space for shipping and provides a more stable stacking pattern allowing sacks to arrive at the customer's facility in better condition; the pre-sealed sack 100 provides more wrinkle free sacks, with all components sealed, allowing for no movement of sacks on filling spouts easy placement of the sacks on filling equipment; the pre-sealed sack 100 allows for easy spouting on both manual and automatic filing equipment because no forming of the sack is necessary with everything pre-sealed; the pre-sealed sack 100 allows for much more accuracy in the final shape with everything held in place; and the pre-sealed sack 100 allows a final seal that permits the end user to open the sack after filling by peeling up the last seal.

Referring now to FIG. 4A there is shown a broken-away view of a corner of a sack blank 300 made in accordance with the present invention with similar reference numerals being used for similar elements shown in the above described embodiments. In this embodiment, the breather openings 187 a comprise a series of small laser cut slits formed in step 154. Placement of the breather openings 187 a in step 154 will slow the escape of air from the sack, and further prevent vermin from entering the sack. In many applications it is desirable if step 154 is (in height—along the longitudinal axis) about 18 mm, step 164 is about 18 mm, and step 160 is about 9 mm. Similarly, in certain applications it is desirable if step 154 is (in height—along the longitudinal axis) about 17 mm, step 164 is about 17 mm, and step 160 is about 11 mm. Alternatively, in many embodiments preferably the height of step 160 is from about 30% to about 60% of the height of step 154, and the height of step 164 is from about 75% to about 125% of the height of step 154. Also, in some embodiments, in order to achieve a stronger closure of the sack, it may be best to place fold line 200 just above the top edge 156 a of step 154. In some applications, preferably, fold line 200 is disposed above top edge 156 a at a distance of from about 4% to about 50% of the height of step 154.

The present disclosure further provides for a method of forming the shipping sack 100. The method generally comprises providing a blank 108 defining a first longitudinal axis and a second axis transverse to the first axis, the blank 108 including a first end and a second end longitudinally spaced from the first end; providing at least one first fold line (e.g., one of fold lines 124, 126) extending parallel to the first axis, the first fold line 124, 126 separating the blank 108 into a first panel 132 and a second panel 134; folding the blank 124 along the first fold line, the blank now defining a tube including open first and second ends (i.e., first end 190), first and second opposed panels 132, 134 and opposed lateral sides 106; providing a pair of spaced second fold lines (i.e., fold line 200, each of the second fold lines extending parallel to the transverse axis, one of the second fold line 200 located on the first panel 132 adjacent the first end, the other of the second fold lines located on the second panel adjacent the second end; folding the first end and the second end along the second fold lines, securing the first end to the second panel 134 to define a closed first end, and securing the second end to the first panel 132 to define a closed second end; and cutting the second panel 134 in a direction parallel to the transverse axis at a location adjacent the first end to form a fill opening 220.

The method further comprises providing a pair of spaced first fold lines 124, 126 which separate the second panel 134 into a pair of second panel sections; folding the blank 108 along the first fold lines 124, 126, the second panel sections having end portions at least partially overlapping, and securing the overlapping end portions of the second panel sections; and cutting the second panel sections to define the fill opening 220. The cutting step can be performed after the first end is folded to define the closed first end or before the first end is folded to define the closed first end. The cutting step further includes spacing opposed ends of the fill opening 220 a predetermined distance from the lateral sides 106 such that the fill opening has a width smaller than a width of the second panel 134.

The method further comprises providing a third fold line 232 extending parallel to the transverse axis and adjacent the fill opening 220, folding the closed first end along the third fold line 232, and securing the folded-over closed first end to the second panel 134 to cover and close the fill opening 220; filling the sack 100 with an associated material through the fill opening 220 prior to the folding of the closed first end; and treating a portion of the second panel 134 which will be engaged with the folded-over closed first end with a release layer 224 to facilitate opening of the sack by pealing open the folded-over closed first end to reveal the fill opening 220.

It is considered apparent that the relative dimensions and locations of seals and openings of the exemplary sack 100 are for illustrative purposes, and that these locations and dimensions may be adjusted without departing from the scope and spirit of the present disclosure.

While, for purposes of simplicity of explanation, the method of forming the sack 100 described above has steps shown and described as executing serially, it is to be understood and appreciated that the present disclosure is not limited by the illustrated order, and some steps could occur in different orders and/or concurrently with other steps from that shown and described herein.

It will be appreciated that various of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Also that various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims. 

What is claimed is:
 1. A shipping sack, comprising: a body including a first end and a second end longitudinally spaced from the first end, opposed lateral sides, and opposed first and second panels, the first end is a first closed end defined by a first end portion of the first panel extending beyond a first end portion of the second panel and the first end portion of the first panel is folded-over and secured to the first end portion of the second panel, the second end is a second closed end defined by a second end portion of the second panel extending beyond a second end portion of the first panel and the second end portion of the second panel is folded-over and secured to the second end portion of the first panel, and the body further including a fill opening located on the second panel, the fill opening extending between the lateral sides and disposed at a location adjacent the first closed end.
 2. The sack of claim 1, wherein the fill opening includes opposed ends, each end is spaced a predetermined distance from the lateral sides such that the fill opening has a width smaller than a width of the body.
 3. The sack of claim 2, wherein each end of the fill opening is spaced about 12 mm to about 25 mm from one of the lateral sides of the body.
 4. The sack of claim 1, wherein the first end portion of the first panel defines an edge and the fill opening is spaced about 55 mm from the edge of the first end portion of the first panel.
 5. The sack of claim 4, wherein the first end portion of the second panel defines an edge and the fill opening is spaced about 10 mm from the edge of the first end portion of the second panel.
 6. The sack of claim 1, wherein the first end portion of the first panel defines an edge and the fill opening is spaced about 62 mm from the edge of the first end portion of the first panel.
 7. The sack of claim 6, wherein the first end portion of the second panel defines an edge and the fill opening is spaced about 14 mm to about 17 mm from the edge of the first end portion of the second panel.
 8. The sack of claim 1, wherein the body includes a first fold line for folding over the first end portion of the first panel to close the first end and define the first closed end, and the body includes a second fold line spaced from the first fold line for folding over the closed first end, the folded-over closed first end is secured to the second panel to close the fill opening.
 9. The sack of claim 8, wherein the first end portion of the first panel defines an edge and the first fold line is spaced about 15 mm to about 28 mm from the edge of the first end portion of the first panel, and the first fold line is spaced about 19 mm to about 38 mm from the second fold line.
 10. The sack of claim 8, wherein the fill opening is located between the first fold line and the second fold line.
 11. A method of forming a shipping sack comprising: providing a blank defining a first longitudinal axis and a second axis transverse to the first axis, the blank including a first end and a second end longitudinally spaced from the first end; providing at least one first fold line extending parallel to the first axis, the first fold line separating the blank into a first panel and a second panel; folding the blank along the first fold line, the blank now defining a tube including open first and second ends, first and second opposed panels and opposed lateral sides; providing a pair of spaced second fold lines, each of the second fold lines extending parallel to the transverse axis, one of the second fold line located on the first panel adjacent the first end, the other of the second fold lines located on the second panel adjacent the second end; folding the first end and the second end along the second fold lines, securing the first end to the second panel to define a closed first end, and securing the second end to the first panel to define a closed second end; and cutting the second panel in a direction parallel to the transverse axis at a location adjacent the first end to form a fill opening.
 12. The method of claim 11, further comprising providing a pair of spaced first fold lines which separate the second panel into a pair of second panel sections; folding the blank along the first fold lines, the second panel sections having end portions at least partially overlapping, and securing the overlapping end portions of the second panel sections; and cutting the second panel sections to define the fill opening.
 13. The method of claim 11, wherein the cutting step is performed after the first end is folded to define the closed first end.
 14. The method of claim 11, wherein the cutting step is performed before the first end is folded to define the closed first end.
 15. The method of claim 11, wherein the cutting step further includes spacing opposed ends of the fill opening a predetermined distance from the lateral sides such that the fill opening has a width smaller than a width of the second panel.
 16. The method of claim 11, further comprising providing a third fold line extending parallel to the transverse axis and adjacent the fill opening, folding the closed first end along the third fold line, and securing the folded-over closed first end to the second panel to cover and close the fill opening.
 17. The method of claim 16, further comprising filling the sack with an associated material through the fill opening prior to the folding of the closed first end.
 18. The method of claim 16, further comprising treating a portion of the second panel which will be engaged with the folded-over closed first end with a release layer to facilitate opening of the sack by pealing open the folded-over closed first end to reveal the fill opening.
 19. A shipping sack, comprising: a body including a first end and a second end longitudinally spaced from the first end, opposed lateral sides, and opposed first and second panels, the first end is a first closed end defined by a first end portion of the first panel extending beyond a first end portion of the second panel and the first end portion of the first panel is folded-over and secured to the first end portion of the second panel, the second end is a second closed end defined by a second end portion of the second panel extending beyond a second end portion of the first panel and the second end portion of the second panel is folded-over and secured to the second end portion of the first panel, and the body further including a fill opening located on the second panel, the fill opening extending between the lateral sides and disposed at a location adjacent the first closed end, the fill opening includes opposed ends, each end is spaced a predetermined distance from the lateral sides such that the fill opening has a width smaller than a width of the body.
 20. The sack of claim 19, wherein the body includes a first fold line for folding over the first end portion of the first panel to close the first end and define the first closed end, and the body includes a second fold line spaced from the first fold line for folding over the closed first end, the fill opening is located between the first fold line and the second fold line, and the folded-over closed first end is secured to the second panel to close the fill opening. 